Triple Glazing with Pyrolytic and Sputtered Low-Emissivity Layers
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Solution Overview
Problem
Current triple glazing systems face limitations in achieving optimal thermal insulation while maintaining high light transmission and neutral color reflection, with existing low-emissive layer systems being either costly or having lower emissivity performance.
Innovation Solution
The implementation of a glazing system where one side of the glass sheet is coated with a pyrolytic layer and the other side with a cathode sputtering layer, with the pyrolytic layer being polished to reduce surface roughness and haze, and using doped tin oxide and intermediate index layers to enhance infrared filtering and color neutrality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple metallic layers and dielectric layers are implemented to improve insulation performance, then thermal insulation is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent combines a pyrolytic low-emissive layer and a sputtered low-emissive layer into a single glazing unit, allowing the merging of two different manufacturing processes and material systems to achieve enhanced thermal insulation without proportionally increasing cost
Solution Approach 2:
The invention uses a composite structure with two distinct low-emissive layer systems (pyrolytic and sputtered) with different properties, creating a multi-functional coating system that optimizes both thermal performance and cost-effectiveness
2Ease of manufacture
If pyrolytic layers are used to reduce manufacturing cost, then ease of manufacture is improved, but emissivity performance deteriorates
Solution Approach 1:
The patent merges a pyrolytic low-emissive layer with a sputtered low-emissive layer in the same glazing unit, combining the cost advantages of pyrolysis with the superior emissivity performance of sputtering to achieve both economical manufacturing and high thermal insulation
Solution Approach 2:
The invention creates a composite coating system where the pyrolytic layer provides cost-effective base insulation while the sputtered layer enhances emissivity performance, resulting in a multi-functional system that balances cost and performance
3Illumination intensity
If the pyrolytic layer surface roughness is reduced through polishing, then light transmission is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies polishing as a preliminary treatment to the pyrolytic layer before final assembly, reducing surface roughness in advance to minimize light scattering and haze, thereby improving light transmission without requiring complex post-processing
Solution Approach 2:
The invention modifies the surface roughness parameter of the pyrolytic layer through controlled polishing, changing the physical state of the surface to reduce light scattering effects while maintaining the low-emissive properties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration achieves a significant improvement in thermal insulation coefficients, with U-values as low as 0.5 W/m²K, while maintaining high light transmission (>60%) and minimal haze (<0.5%), and neutral color reflection, surpassing previous glazing performance standards.
Implementation Method 1
thin transparent layers acting as selective filters for the transmitted wavelengths
Implementation Method 2
thin metallic layers which selectively reflect infrared rays
Implementation Method 3
the pyrolytic layer being polished to reduce surface roughness and haze
Data Source
Figure 1~3
AI summary
The invention relates to triple glazing comprising at least one glass sheet that has a system of layers on one side which are produced using sputtering and include at least one metal layer that reflects infrared radiation. The at least one glass sheet has a set of low-emission layers on the other side, said set of layers comprising one or more oxide layers that are deposited using gas phase pyrolysis. The disclosed glazing has a minimum light transmittance of 60 percent (standard EN 410, illuminant D65 at 2°) with 4 mm thick glass sheets.